OLED pixel structure and method for manufacturing the same

ABSTRACT

An organic light emitting display (OLED) pixel structure and a method for manufacturing the same, which can be applied for improving the resolution of an OLED without significantly changing the current OLED manufacturing process. With a novel pixel arrangement and circuit layout, an organic light emitting material is evaporated onto a substrate through a mask and thus a plurality of sub-pixels are formed simultaneously while enabling each sub-pixel to correspond to different pixels. Thereby, the area of each sub-pixel is reduced and the resolution of a display is increased.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an organic light emittingdisplay (OLED) pixel structure and a method for manufacturing the sameand, more particularly, to an OLED pixel structure and a method formanufacturing the OLED pixel structure using a novel pixel arrangementso as to improve the resolution of an OLED panel.

2. Description of the Prior Art

In OLED manufacturing, full color displays implemented using red (R),green (G) and blue (B) organic electro-luminescent (EL) materialsexhibit high brightness, high contrast, high color saturation but sufferfrom limited resolution because the opening areas on the shadow mask forEL material evaporation can not be effectively reduced.

Please refer to FIG. 1, which is a schematic diagram showing anevaporation process for an organic EL material. In mass production, thecurrent EL evaporation process uses a single EL source in a vacuumchamber. As shown in FIG. 1, a shadow mask 10 is disposed between asubstrate 12 and an EL source 14, wherein the surface of the substrate12 to be deposited thereon faces downwards to the EL source 14. When theEL source 14 is heated up, the organic EL material is evaporated througha plurality of openings 102 in the shadow mask 10 onto a plurality ofdeposited regions 122 on the substrate 12. By shifting the shadow mask10 and the substrate 12, the EL source 14 evaporates the organic ELmaterial for one of the three colors onto the pre-determined depositedregions 122 and then evaporates the organic EL materials for each of theother two colors. Finally, the organic EL materials for R, G and B areformed on the deposited regions 122 on the substrate 12, wherein each ofthe deposited regions 122 corresponds to a sub-pixel.

Please refer to FIG. 2, which is a schematic circuit diagram showingequivalent pixel circuits and driver circuits of an OLED panel. The OLEDpanel 20, using two thin-film transistors (TFT's) for example, comprisesdata lines D1, D2, . . . , Dm and scanning lines G1, G2, . . . , Gn.Each data line and an intersecting scanning line are used to control adisplay unit 21. For example, a switching transistor T_(S11) comprisesthe gate coupled to a scanning line G1 and the source coupled to a dataline D1 for storage and addressing of an image data. A drivingtransistor T_(D11) comprises the gate coupled to the drain of theT_(S11) and the source coupled to a voltage source V_(DD) forcontrolling the driving current according to the storage capacitorC_(S11). One end of the storage capacitor C_(S11) is coupled to thedrain of the T_(S11) while the other end is coupled to a referencevoltage VL. The anode of the OLED is coupled the drain of the T_(D11)and the cathode is coupled to the ground GND.

The schematic circuit diagram of FIG. 2 comprises the switchingtransistors T_(S11)˜T_(S1m), T_(S21)˜T_(S2m), . . . , T_(Sn1)˜T_(Snm),the driving transistors T_(D11)˜T_(D1m), T_(D21)˜T_(D2m), . . . ,T_(Dn1)˜T_(Dnm), the storage capacitors C_(S11)˜C_(S1m),C_(S21)˜C_(S2m), . . . , S_(Sn1)˜C_(Snm), and the OLED's. Each displayunit 21 corresponds to a sub-pixel. A pixel comprises three sub-pixelsfor R, G and B corresponding to three display units. In other words, inFIG. 1, when the organic EL material is evaporated through the pluralityof openings 102 in the shadow mask 10 onto the plurality of depositedregions 122 on the substrate 12, the area of one of the openings 102corresponds to the area of a sub-pixel. Each sub-pixel corresponds totwo TFT's and one storage capacitor.

Please refer to FIG. 3A and FIG. 3B, which are schematic diagramsshowing pixel arrangements of an OLED panel. In FIG. 3A, there are aplurality of pixels 31 comprising a red sub-pixel 312, a green sub-pixel314 and a blue sub-pixel 316 on an OLED panel 30. Each sub-pixelcorresponds to two TFT's and one storage capacitor as shown in FIG. 2.Moreover, sub-pixels with different colors have different life-times.The sub-pixel with the shortest life-time limits the durability of wholedisplay panel. If the red sub-pixel and the blue sub-pixel, whichexhibit lower brightness, are designed to have larger areas, the drivingcurrents for the red sub-pixel and the blue sub-pixel could be loweredso as to enhance the durability of whole display panel. In FIG. 3B,there is a white (W) sub-pixel 368 in addition to a red sub-pixel 362, agreen sub-pixel 364 and a blue sub-pixel 366 in each of the pixels 36 onthe OLED panel 35. The red sub-pixel 362, the green sub-pixel 364, theblue sub-pixel 366 and the white sub-pixel 368 may have different areas.Since each of the sub-pixels corresponds to two TFT's and one storagecapacitor as shown in FIG. 2 and the area of each of the sub-pixels isdetermined by the opening 102 of the shadow mask 10. In other words, thesub-pixel area formed by evaporating an organic EL material through theopening 102 of the shadow mask 10 onto the deposited region 122 can notbe unlimitedly reduced. Therefore, the resolution of the OLED panel islimited by the evaporation process.

Therefore, there exists a need in providing an OLED pixel structure anda method for manufacturing the OLED pixel structure using a novel pixelarrangement so as to improve the resolution of an OLED panel.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to provide an OLED pixelstructure and a method for manufacturing the OLED pixel structure usinga novel pixel arrangement so as to improve the resolution of an OLEDpanel. The organic EL material for R, G, B or W is heated up andevaporated through an opening of a shadow mask onto a plurality ofdeposited regions on a substrate. The deposited regions with theevaporated organic EL material are categorized into a plurality ofgroups of sub-pixels with the same color, wherein each of the sub-pixelscorresponds to different pixels. Therefore, the organic EL materialevaporated through one single opening onto one deposited region can beused for multiple sub-pixels so as to effectively reduce the sub-pixelarea and hence improve the resolution of an OLED panel.

It is a secondary object of the present invention to provide an OLEDpixel structure and a method for manufacturing the OLED pixel structureusing a novel pixel arrangement so as to improve the resolution of anOLED panel without significantly changing the current OLED manufacturingprocess. The present invention can be used in both bottom-emission andtop-emission OLED's.

In order to achieve the foregoing objects, the present inventionprovides a method for manufacturing an organic light-emitting device(OLED) pixel structure, comprising steps of: providing a substrate;forming a plurality of thin-film transistors on the substrate; defininga plurality of deposited regions on the plurality of thin-filmtransistors; and evaporating an organic electro-luminescent (EL)material through an opening of a shadow mask onto at least two of thedeposited regions, wherein each of the deposited regions with theevaporated organic electro-luminescent material is a sub-pixelcorresponding to different pixels.

The present invention further provides a substrate; a plurality ofthin-film transistors formed on the substrate; a plurality of depositedregions defined on the plurality of thin-film transistors; and anorganic electro-luminescent (EL) layer formed on the deposited regions,wherein each of the deposited regions coated with the organicelectro-luminescent material is a sub-pixel corresponding to differentpixels.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects, spirits and advantages of the preferred embodiments of thepresent invention will be readily understood by the accompanyingdrawings and detailed descriptions, wherein:

FIG. 1 is a schematic diagram showing an evaporation process for anorganic EL material;

FIG. 2 is a schematic circuit diagram showing equivalent pixel circuitsand driver circuits of an OLED panel;

FIG. 3A and FIG. 3B are schematic diagrams showing pixel arrangements ofan OLED panel;

FIG. 4A to FIG. 4E are cross-sectional views showing an OLED pixelstructure according to the present invention;

FIG. 5A is a schematic diagram showing a pixel arrangement of an OLEDpanel according to a first embodiment of the present invention;

FIG. 5B is a schematic diagram showing a pixel arrangement of an OLEDpanel according to a second embodiment of the present invention; and

FIG. 6 is a schematic diagram showing a pixel arrangement of an OLEDpanel according to a third embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention providing an OLED pixel structure and a method formanufacturing the same can be exemplified by the preferred embodimentsas described hereinafter.

Please refer to FIG. 4A to FIG. 4E for the cross-sectional views showingan OLED pixel structure according to the present invention. In FIG. 4A,a substrate 401 is provided. On the substrate 401, in addition tothin-film transistors 41, there are formed a buffer layer 402, a gatedielectric layer 403, a first protective layer 404, an isolating layer405 and a second protective layer 406. One of the source/drain regionsof each of the thin-film transistors 41 is coupled to a pixel electrode(anode) 42. Deposited regions 43 are formed on the pixel electrode 42.Moreover, an insulating layer 407 is formed on the isolating layer 405so as to distinguish the sub-pixels R, G, B. In FIG. 4B, an organicelectro-luminescent (EL) material for red is evaporated through anopening 445 of a shadow mask 44 onto the deposited region 43 for asub-pixel R. Therefore, an organic electro-luminescent layer 45 for redis formed. As shown in FIG. 4C, an organic electro-luminescent materialfor green is evaporated through the opening 445 of the shadow mask 44onto the deposited region 43 for a sub-pixel G. Therefore, an organicelectro-luminescent layer 46 for green is formed. As shown in FIG. 4D,an organic electro-luminescent material for blue is evaporated throughthe opening 445 of the shadow mask 44 onto the deposited region 43 for asub-pixel B. Therefore, an organic electro-luminescent layer 46 for blueis formed. Finally in FIG. 4E, a pixel electrode (anode) 48 is formed onthe organic electro-luminescent layers 45, 46, 47 so that a pixelstructure is formed to comprise an R sub-pixel, a G sub-pixel and a Bsub-pixel. Each sub-pixel comprises a thin-film transistor 41 as itsdriving transistor.

Please refer to FIG. 5A, which is a schematic diagram showing a pixelarrangement of an OLED panel according to a first embodiment of thepresent invention. An OLED panel 50 comprises a plurality of pixels 51.Using evaporation, a rectangular region for red 52 comprising four redrectangular sub-pixels 521 is formed. Each of the red rectangularsub-pixels 521 corresponds to different pixels 51. Similarly, arectangular region for green 53, a rectangular region for blue 54 and arectangular region for white 55 are formed using evaporation. Each offour green rectangular sub-pixels 531 in the rectangular region forgreen 53 corresponds to different pixels 51. Each of four bluerectangular sub-pixels 541 in the rectangular region for blue 54corresponds to different pixels 51. Each of four white rectangularsub-pixels 551 in the rectangular region for white 55 corresponds todifferent pixels 51. In other words, each pixel 51 is composed of a redrectangular sub-pixel 521, a green rectangular sub-pixel 531, a bluerectangular sub-pixel 541 and a white rectangular sub-pixel 551. In theprior art, the opening has a certain area, which limits the sub-pixelarea. However, with the pixel arrangement of the present invention,multiple sub-pixels of the same color can be formed in one evaporationprocess for different pixels. Therefore, the sub-pixel for one pixel isdown-sized and thus the resolution of an OLED panel can be effectivelyimproved.

Please refer to FIG. 5B, which is a schematic diagram showing a pixelarrangement of an OLED panel according to a second embodiment of thepresent invention. Since the durability of an OLED panel depends on thesub-pixel with the shortest life-time, the sub-pixel with the shortestlife-time can be designed to have the largest area without changing theevaporation process so as to improve the durability of the OLED panelaccording to the present invention. For example, the rectangular regionfor white 55 in FIG. 5A can be used to deposit the organic EL materialfor red so that all the rectangular regions for white 55 in FIG. 5A arereplaced by the rectangular regions for red 52. Accordingly, the organicEL material for red occupies twice the area and thus the red sub-pixelsshare a larger luminescent area. Under the same luminescent intensity,the driving current for the red sub-pixels can be lowered so as toimprove the durability of the OLED panel.

Please refer to FIG. 6, which is a schematic diagram showing a pixelarrangement of an OLED panel according to a third embodiment of thepresent invention. An OLED panel 60 comprises a plurality of pixels 61.In the first embodiment as shown in FIG. 5A, the rectangular region forred 52, the rectangular region for green 53, the rectangular region forblue 54 and the rectangular region for white 55 are formed byevaporating organic EL materials through the opening with theidentically small area for all the sub-pixels. Therefore, a highestresolution is obtained using the identically small area for the redrectangular sub-pixels 521, the green rectangular sub-pixels 531, theblue rectangular sub-pixels 541 and the white rectangular sub-pixels 551because the opening area of the shadow mask can not be unlimitedlydown-sized. However in the third embodiment as shown in FIG. 6, theareas for the red rectangular sub-pixels 621, the green rectangularsub-pixels 631, the blue rectangular sub-pixels 641 and the whiterectangular sub-pixels 651 can be different according to practical use.Different opening areas can be selected when evaporating the organic ELmaterials onto the rectangular regions for red 62, the rectangularregions for green 63, the rectangular regions for blue 64 and therectangular regions for white 65. For example, the rectangular regionsfor red 62 require the largest area and therefore a shadow mask with alargest opening area is selected when evaporating the EL material ontothe rectangular regions for red 62. On the contrary, the rectangularregions for green 63 require the smallest area and therefore a shadowmask with a smallest opening area is selected when evaporating the ELmaterial onto the rectangular regions for green 63. After therectangular regions for red 62, the rectangular regions for green 63,the rectangular regions for blue 64 and the rectangular regions forwhite 65 are formed using evaporation, each of the pixels 61 comprises ared rectangular sub-pixel 621, a green rectangular sub-pixel 631, a bluerectangular sub-pixel 641 and a white rectangular sub-pixel 651. Eachsub-pixel area is different. Even though the resolution of the OLEDpanel 60 in FIG. 6 is superior to the resolution of the OLED panel 50 inFIG. 5A, the resolution of the OLED panel 60 is still higher than theresolution of conventionally manufactured OLED panel. The thirdembodiment of the present invention provides OLED panel designers withgreater flexibility since the areas of sub-pixels for different colorsare not identical.

It is to be noted that the cross-sectional views in FIG. 4A to FIG. 4Eare only exemplary. The present invention can be used in bothbottom-emitting and top-emitting pixel structures. The substrate used inthe present invention can be a flexible substrate, a glass substrate ora metal substrate. The transistors of the present invention are notlimited to a certain type of transistors. The transistors of the presentinvention can be implemented using a bottom gate or a top gate,amorphous silicon, poly-silicon or an organic material so as to beadapted in the OLED pixel structure and the method for manufacturing thesame.

According to the above discussion, it is apparent that the presentinvention discloses an OLED pixel structure and a method formanufacturing the OLED pixel structure using a novel pixel arrangementso as to improve the resolution of an OLED panel without significantlychanging the current OLED manufacturing process. Therefore, the presentinvention is novel, useful and non-obvious.

Although this invention has been disclosed and illustrated withreference to particular embodiments, the principles involved aresusceptible for use in numerous other embodiments that will be apparentto persons skilled in the art. This invention is, therefore, to belimited only as indicated by the scope of the appended claims.

1. A method for manufacturing an organic light-emitting device (OLED)pixel structure, comprising steps of: providing a substrate; forming aplurality of thin-film transistors on the substrate; defining aplurality of deposited regions on the plurality of thin-filmtransistors; and evaporating an organic electro-luminescent (EL)material through an opening of a shadow mask onto at least two of thedeposited regions, wherein each of the deposited regions with theevaporated organic electro-luminescent material is a sub-pixelcorresponding to different pixels.
 2. The method for manufacturing anOLED pixel structure as recited in claim 1, wherein the organicelectro-luminescent material is one of an organic electro-luminescentmaterial for red, an organic electro-luminescent material for green, anorganic electro-luminescent material for blue and an organicelectro-luminescent material for white.
 3. The method for manufacturingan OLED pixel structure as recited in claim 1, wherein the depositedregions with the evaporated organic electro-luminescent material areadjacent to one another.
 4. The method for manufacturing an OLED pixelstructure as recited in claim 1, wherein the deposited regions with theevaporated organic electro-luminescent material comprise a plurality ofsub-pixels with an identical area, each sub-pixel corresponding todifferent pixels.
 5. The method for manufacturing an OLED pixelstructure as recited in claim 1, wherein the pixel comprises a redsub-pixel, a green sub-pixel and a blue sub-pixel.
 6. The method formanufacturing an OLED pixel structure as recited in claim 1, wherein thepixel comprises a red sub-pixel, a green sub-pixel, a blue sub-pixel anda white sub-pixel.
 7. The method for manufacturing an OLED pixelstructure as recited in claim 1, wherein the deposited regions with theevaporated organic electro-luminescent material comprise a plurality ofrectangular sub-pixels, each rectangular sub-pixel corresponding todifferent rectangular pixels.
 8. An organic light-emitting device (OLED)pixel structure, comprising: a substrate; a plurality of thin-filmtransistors formed on the substrate; a plurality of deposited regionsdefined on the plurality of thin-film transistors; and an organicelectro-luminescent (EL) layer formed on the deposited regions, whereineach of the deposited regions coated with the organicelectro-luminescent material is a sub-pixel corresponding to differentpixels.
 9. The OLED pixel structure as recited in claim 8, wherein theorganic electro-luminescent (EL) layer is formed using an evaporationprocess.
 10. The OLED pixel structure as recited in claim 8, wherein theorganic electro-luminescent layer comprises an organicelectro-luminescent material for red, an organic electro-luminescentmaterial for green and an organic electro-luminescent material for blue.11. The OLED pixel structure as recited in claim 8, wherein the organicelectro-luminescent layer comprises an organic electro-luminescentmaterial for red, an organic electro-luminescent material for green, anorganic electro-luminescent material for blue and an organicelectro-luminescent material for white.
 12. The OLED pixel structure asrecited in claim 8, wherein the deposited regions with the evaporatedorganic electro-luminescent layer are adjacent to one another.
 13. TheOLED pixel structure as recited in claim 8, wherein the depositedregions with the evaporated organic electro-luminescent layer comprise aplurality of sub-pixels with an identical area, each sub-pixelcorresponding to different pixels.
 14. The OLED pixel structure asrecited in claim 8, wherein the deposited regions with the evaporatedorganic electro-luminescent layer comprise a plurality of rectangularsub-pixels, each rectangular sub-pixel corresponding to differentrectangular pixels.